Brake Caliper Replacement. Chevrolet PJJ 2000

For 1990-2009 cars

### Removal Procedure

1. Remove and discard 2/3 of the brake fluid from the master cylinder assembly.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Install 2 wheel nuts in order to retain the brake rotor on the hub.
4. Push the piston into the caliper bore in order to provide clearance between the linings and the rotor.
5. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe.

Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough in order to slide the caliper assembly off the rotor.

6. Remove the front brake hose retaining bolt only when the brake caliper is removed from the vehicle for overhaul. If only the shoe and linings are being replaced, you do not need to disconnect the front brake hose retaining bolt.
7. Plug the brake hose in order to prevent fluid loss or contamination.
8. Remove the brake caliper mounting bolts.
9. Remove the brake caliper (2) from the brake rotor and steering knuckle.

• | Do not let the brake caliper (2) hang from the brake hose. Damage may occur.

• | If the brake caliper is not being removed from the vehicle for overhaul, suspend the brake caliper with a wire hook from the strut (1).

10. Inspect the brake caliper mounting bolts (1) and sleeve (4) assemblies for corrosion.
11. Inspect the bushings (2) for cuts and nicks.

Important: Do no attempt to polish away corrosion.

12. If damage to either part is found, replace with new parts when you install the caliper.

### Installation Procedure

1. Liberally coat the inside of the diameter of the bushings (4) with silicone grease (4).
2. Install the brake caliper (2) over the brake rotor into the steering knuckle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the brake caliper mounting bolts.

Tighten
Tighten the brake caliper mounting bolts 51 N·m (38 lb ft).

4. Install new sealing washers on the brake hose bolt.
5. Install the brake hose retaining bolt.

Tighten
Tighten the front brake hose retaining bolt to 44 N·m (32 lb ft).

6. Remove the 2 wheel nuts used to retain the brake rotor to the hub.
7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
10. Bleed the hydraulic brake system if the brake caliper was removed. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.